Copper-Plated Iron Frangible Projectile Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing frangible projectiles face challenges in being cost-effective, reliable, and effectively disintegrating upon impact while minimizing damage and risk of ricochet, with previous designs often using lead or other heavy metals and encountering issues like sparking when hitting metal targets.
Innovation Solution
A frangible projectile composed of a pressed or sintered mass of copper or copper alloy plated iron or iron alloy core particles, with particle sizes between 12 μm and 336 μm, which reduces the risk of sparking and maintains weight similar to conventional projectiles, using commercially available iron powders and electrochemical or chemical plating methods to achieve desired mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lead or heavy metals are used in frangible projectiles, then weight and stopping power are improved, but cost increases and toxicity concerns arise
Solution Approach 1:
The patent uses composite iron-copper particles where iron provides density and weight comparable to lead, while copper plating prevents sparking and enables controlled disintegration. This composite structure achieves lead-like ballistic properties without the toxicity and cost issues of lead.
Solution Approach 2:
The frangible projectile is designed as a disposable item that disintegrates after single use. Using inexpensive iron-copper composite particles instead of expensive lead allows for cost-effective single-use ammunition that meets safety and performance requirements.
2Strength
If conventional solid projectiles are used, then structural integrity and range are improved, but risk of ricochet and property damage increases
Solution Approach 1:
The projectile is segmented into numerous fine iron-copper particles (1-10 micrometers) held together by binding agents. Upon impact, these segments easily separate and disperse, preventing ricochet while maintaining sufficient structural integrity during flight through the binding agents.
Solution Approach 2:
The patent changes the physical parameters of the projectile by using extremely fine particle sizes (1-10 micrometers) with specific surface area-to-volume ratios. This parameter change enables the projectile to maintain structural integrity during flight yet disintegrate easily upon impact, reducing harmful effects.
3Ease of manufacture
If iron particles are used without plating, then cost is reduced, but sparking risk when hitting metal targets increases
Solution Approach 1:
A thin copper plating is applied as an intermediary layer on the iron particles. This copper coating prevents direct contact between iron and metal targets, eliminating sparking risk while adding minimal cost and maintaining the frangible properties of the iron core.
4Reliability
If particle size is reduced for better disintegration, then frangible performance is improved, but handling and charging difficulty increases
Solution Approach 1:
The patent optimizes particle size parameters to 1-10 micrometers, which is fine enough to ensure reliable disintegration upon impact but coarse enough to maintain manageable flow characteristics for handling and charging. Binding agents are also adjusted to compensate for the fine particle size.
Solution Approach 2:
Binding agents serve as intermediaries that hold the fine iron-copper particles together during handling and charging, preventing them from scattering or clogging. These binders release easily upon impact, allowing the particles to disintegrate as intended.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The copper-plated iron projectiles effectively disintegrate upon impact, reducing the risk of damage and ricochet while maintaining a low cost and weight comparable to conventional projectiles, and eliminating the need for lead or other heavy metals, thereby enhancing safety and performance.
Implementation Method 1
The copper or copper alloy plating can be applied by any suitable method, such as chemical or electrochemical plating
Implementation Method 2
The copper or copper alloy plating can be applied by any suitable method, such as chemical or electrochemical plating
Implementation Method 3
a pressed or sintered mass of a plurality of copper or copper alloy plated core particles of iron or an iron alloy
Data Source
AI summary
A frangible projectile includes a sintered mass of a plurality of copper or copper alloy plated iron or iron alloy core particles.